Cardboard carton



Feb. 17, 1970 I A. w. PAscus E AL 3,

CARDBOARD CARTON Filed May 25, 1968 v 5 Sheets-Sheet 1 FIGIA filo INVENTORS. AW. PASCUS EDMUND BOEHM ATTORNEYS.

Feb. 17,1970 A.w. PAsus ETAL 3,4955751 CARDBOARD CARTON Filed May 25, 1968 3 Sheets-Sheet 2 Flee ll" 92 W4 91 In I C24 '11 I, 84 ll gg as m 46 Hu /7a 40 %O4 l 90 im I M Feb. 17,1970 YIA,W,PII \SC:UYSQET AL 3,495,151

' cmnsoAnbi-cmrou Filed May 23, 1968 v a Sheets-Sheet} I; il :11 i 29o 292 278 1* Hu 228 'M Hm.

m 96 5 FIG.3 i 34 United States Patent O US. Cl. 229-33 3 Claims ABSTRACT OF THE DISCLOSURE A carton formed from a generally rectangular laminated blank including outer plies and a corrugated core with the corrugations extending generally diagonally across the blank. The blank includes a rectangular bottom panel surrounded by pairs of parallel fold lines defining side panels with generally triangularly shaped top panels connected to the outermost fold lines of the side panels. Preferably corner gussets are foldably connected to opposite pairs of side panels with locking tabs on the upper surface of the gussets and locking notches on the underside of the top of the triangular flaps to receive the locking tabs of the gussets. The underside of one triangular top panel and the diametrically opposite surface of an opposite triangular top panel are coated with adhesive means to secure the closure created when the several panels are folded inwardly upon each other. The different fold lines of the carton may be offset relative to each other to properly locate the folded elements with respect to each other to afford a compact rigid, stressfree closure.

BACKGROUND OF THE INVENTION Field of the invention This invention relates in general to the box or carton art, and more particularly, to a box or carton formed from a blank of laminated material including two spaced plies of paper or the like separated by a corrugated core of paper or the like, and wherein the blank is oriented so that the corrugations extend generally diagonally of the rectangular structures defined therein.

BRIEF DESCRIPTION OF THE PRIOR ART The prior art relating to generally rectangular blanks having rectangular areas delimited by pairs of parallel score lines to define upstanding side walls and hingedly connected triangular shaped top fiap portions is represented by the patents to Pryor 3,252,650, Berniss 2,987,237 and Stubbs 1,774,299. A significant problem in the art of corrugated cardboard cartons is to provide sufficiently rigid wall structure to afford a resultant rigid and durable container which will withstand the rigors of shipment through the mail and the like. In addition, suitable reinforcing and locking structure should be afforded to prevent unintended collapse and/or opening of the structure during transit thereof. While the aforementioned patents generally show triangular fiap cartons made from rectangular :blanks, the cartons shown possess the shortcomings of being inadequately provided with structural means for facilitating a secure closure once assembled and a rigid and durable container which may be easily assembled and adequately protect the contents wrapped therein against unintended or accidental destruction of the container or access to the interior thereof. Thus, a need has arisen to provide a cardboard carton formed from a generally rectangular blank having the desirable qualities discussed herein.

SUMMARY OF THE INVENTION This invention is directed, in brief, to the provision of a cardboard carton formed from a laminated blank of outer plies and a corrugated core. The best mode contemplated by us for carrying out the invention comprises a blank wherein the corrugations extend generally diagonally relative to the component portions of the rectangular blank. The blank includes a generally rectangular base area surrounded by pairs of parallel score lines defining side wall portions which terminate in triangular flap portions. In a preferred form, opposite pairs of narrow side wall portions have laterally extending gussets with locking tabs at the top portions of the gussets. Adjacent transverse-1y extending top flap structures have U- shaped cutouts in one face of the lamination for receiving the tabs on the gussets when the gussets are folded inwardly upon the adjacent side panel and the side panel is folded inwardly towards the rectangular blank section. As the subsequent triangular top portions are folded upon each other, the tabs securely lock in the undersides thereof.

In another form, locking nibs extend outwardly from side edges=of opposite flaps and laterally adjacent side walls have notches for receiving the locking nibs.

In addition, the diametrically opposed top flap portions are provided with mutually adherent cementitious substance such as contact cement or the like, so that when opposite flaps are folded upon each other the coated underside of one flap will tenaciously adhere to the coated upper side of the other flap to secure the carton together as a closed unit. A means such as the well-known zipper opening may be provided for gaining easy access to the interior of the carton by the intended recipient or user thereof.

Other features of the invention will. be readily apparent to those skilled in the art from the following description, taken in connection with the annexed drawing:

DESCRIPTION OF THE DRAWINGS invention;

FIGURE 4 is a plan view of another modified form of this invention;

FIGURE 5 is a fragmentary enlarged sectional view showing the relationship of components of the carton blank of FIGURE 4 when the blank is folded upon itself to form a carton;

FIGURE 6 is a plan view of the blank shown in FIGURE 1 with portions thereof folded upon itself in an intermediate step of forming the enclosure as shown in FIGURE 2; and

FIGURE 7 is a fragmentary enlarged sectional view through the assembled portion. of the blank shown in FIGURE 6 illustrating the relationship of the components of the blank in the assembled condition.

DESCRIPTION OF THE PREFERRED EMBODIMENT While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail embodiments of the invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention and the embodiments illustrated. The scope of the invention will be pointed out in the appended claims.

Referring now to the drawings, the carton of this invention is formed from a rectangular blank, such as the illustrated square blank 10, preferably of the type comprising a lamination of corrugation 11 sandwiched between two outer plies 11a and 11b. Preferably the corrugations run parallel and transverse to the opposed pair of edges of the blank, or, in other words, diagonally pf the elements of the blank to be described. The blank includes a generally rectangularly shaped bottom panel 12 defined by parallel fold lines 14 and 16 extending along the length of the long sides of the rectangle as illustrated, and pairs of spaced parallel fold lines 18 and 20 generally transverse to lines 14 and 16 and extending along the width or short sides of the panel 12 illustrated. (Where bottom panel 12 is square, all sides will be of equal length.) Fold lines 22 and 24 extend generally parallel to fold lines 14 and 16, respectively, and define therebetween long side panels 26 and 28, respectively. Fold lines 30 and 32 extend generally parallel to fold lines 18 and 20, respectively, and define therebetween short side panels 34 and 36, respectively. Filling out substantially the remainder of the rectangular blank are substantially triangularly shaped large flaps 38 and 40 lying outside of fold lines 22 and 24, respectively, and triangularly shaped small flaps 42 and 44 lying outside of fold lines 30 and 32, respectively.

A substantial portion of the blank areas between the side wall panels is utilized to provide corner gussets 46, 48, 50 and 52. Gussets 46 and 48 are articulated to opposite ends of side wall panel 34 by fold lines 54 and 56, respectively. Similarly, gussets 50 and 52 are articulated to opposite ends of side wall panel 36 by means of fold lines 58 and 60, respectively. In addition, gussets 48 and 52 are separated from side panel 26 and flap 38 by cuts 62 and 64, respectively, each of which extends completely through the blank and terminates in inwardly directed offset cut portions 62a and 64a, respectively. Similarly, gussets 46 and 50 are separated from side panel 28 and flap 40 by cuts 66 and 68, respectively, each of which extends completely through the blank and which further terminates in inwardly directed portions 66a and 68a, respectively. Each of the inwardly directed portions 62a, 64a, 66a and 68a terminates generally in the area of the intersection of fold lines 14, 20, 16 and 18, or, in other words, approximately in the area of the four corners of the bottom panel 12.

Opposite side edges 70 and 72 of flap 42 and 74 and 76 of flap 44 are spaced inwardly from the articulating lines 54-56, respectively, and 58-60, respectively, a distance generally equal to the thickness of the blank. In turn, these gusset articulating lines such as 56 and 60 are spaced inwardly from fold line 14 and 54 and 58 are spaced inwardly from fold line 16 also a distance generally equal to the thickness of the blank for a purpose to be explained later.

Each of corner gussets 46, 48 and 50, 52 is provided with a generally outwardly extending locking tab 78, 80, 82 and 84, respectively. The underside of the triangular flaps 38 and 40 are provided with U-shaped cutouts, such as the cutouts 86 and 88 in flap 38 and 90 and 92 in flap 40. These cutouts are located along the fold lines 22 and 24 and also adjacent the cut edges 62, 64, 66 and 68 so that, when the carton is folded upon itself in the assembled condition, the several tabs 78 through 84 will engage the notches, with tab 78 engaging notch 90, tab 80 engaging notch 86, tab 82 engaging notch 88 and tab 84 engaging notch 92; to securely lock the gussets in position and prevent unintended or accidental withdrawal therefrom. Preferably the U-shaped cutouts extend only through the sheet 11b of the laminations so as to not protrude through the exterior of the completed carton, retaining a smooth exterior and a clean overall appearance.

A generally circular cutout is formed in the blank in the areas between the short triangular flaps and the corner gussets, such as the cutout 94 mostly in gusset 46, the cutout 96 mostly in gusset 48, the cutout 90a mostly in gusset 52 and the cutout 100 mostly in gusset 50. These cutouts provide a clearance for the tabs so as to facilitate a good grab of each of the locking tabs in each of the U-shaped notches when the box or carton is in the assembled condition.

Adhesive means are provided on opposite triangular flaps to provide a means for maintaining the carton in the closed condition when the several elements are folded upon each other. Preferably, the adhesive comprises the type which tenaciously adheres to itself, but does not adhere to dissimilar subjects, such as the type known as contact cements or the like. Also, it is preferable that the adhesive be located on diametrically opposite portions of the blank such as providing a disposition of adhesive 102 on face 38a of flap 38 and further disposing a portion 104 on face 40a of flap 40. This provides the advantage that when the blanks are stacked in a flattened condition, the adhesive portions will not come in direct contact with each other and yet, when the flaps are folded upon themselves to provide the completed carton, portion 102 will directly underlie portion 104 so that the two may intimately engage and tenaciously adhere to each other to maintain the enclosure afforded by the several folding steps.

It is also preferable that the entire periphery of the blank be serrated so as to prevent the likelihood of annoying finger cuts or the like as is common with straight cardboard or paper edges. If desired, a zipper type opening 106 well known in the art could be provided for gaining access to the package by the intended recipient or user thereof.

In assembly, the short side panels 34 and 36 are folded inwardly about the lines 18 and 20 to a generally upright position. Then the flaps 42 and 44 are folded about fold lines 30 and 32, respectively, so that they generally overlie the base panel 12. The corner gussets 46, 48, 50 and 52 are folded inwardly about the lines 54, 56, 58 and 60, respectively, until they lie just inside of, and extend parallel to, the fold lines 14 and 16.

As best seen in FIGURE 6, the gussets, such as 48 and 52 lie just outside the edges of the small triangular flap, such as the edges 70 and 76, so that the tabs and 82 may project slightly above the top surface of flaps 42 and 44. Yet, the gussets also lie just inside the fold lines for the long side panels such as the fold line 14, so that when the side panels are folded upwardly, the gussets will not interfere with the upward folding movement of the side panels. The following steps in assembly are to fold one long side panel such as the panel 26 upwardly about the fold line 14 and then fold the adjacent triangular flap inwardly about the fold line such as fold line 22 so that the flap 38 having the adhesive 102 on the face 38a thereof will be facing upwardly or outwardly as shown in FIGURE 6. With the parts so oriented, the final step of assembly may be accomplished by folding side panel 28 upwardly about fold line 16 and then folding triangular flap 40 about line 24 to bring the adhesive portion 104 into facial contact with adhesive portion 102 causing tenacious adherence thereof. When the triangular panels 40 and 38 are folded downwardly over the panels 42 and 44, the tabs 80, 82, 84 and 78 engage in the notches 86, 88, 92 and respectively, as seen in FIGURE 7. This locks the side panels 34 and 36- in their respective flaps 42 and 44 against withdrawal from the completed package. In addition, it holds the corner gussets 46, 48, 50 and 52 in an upright position wherein they exercise the function of providing added upstanding beam strength to the carton resisting the imposition of heavy loads in maintaining the carton in its assembled condition and protecting the contents thereof against crushing.

It is to be further noted that the fold lines for the side panels, such as fold lines 18 and 20, extend slightly inside of the cut edges 62, 66 and 64, 68, respectively, which define the side edges of flaps 38 and 40, so that when the side panels 34 and 36 are folded upwardly they are coextensive in the assembled condition with the edges defined by lines 62, 64, 66 and 68 and do not protrude outwardly therefrom. It is to be further noted that the terminal ends of the cut 62-68 are directed inwardly as at 62a, 64a, 66a and 68a so that when the several gussets 46 through 52 are folded inwardly and the short side panels are folded about the fold lines 18 and 20, there will be no stress imposed tending to force the assembly outwardly. In other words, the bottom line formed by the bottom edge of the gusset will lie, in the assembled condition, coplanar with the top of the bottom panel 12, assuming this position without the tendency for the gusset to be forced upwardly and away from the panel, other than the tendency that would be imposed thereupon by the resistance in fold lines such as 18 and 20. The gussets 46 through 52 also serve to enclose each of the four corners of the completed carton and the locking tabs, by preventing the reserve withdrawal of the structure associated with panels 30, 36 and flaps 42, 44, insure that the four corners will be maintained in a closed condition. Because the blank is cut from cardboard stock so that the corrugations run on a diagonal relative to the several panels, the gussets, when in the upright assembled position present mutually inwardly and upwardly directed beam elements in the form of corrugations themselves which extend at a generally 45 angle relative to the bottom panel 12 giving added strength to the gussets as well as to the locking tabs, which is important to maintain the structure in a locked and assembled condition.

A simplified form of the cardboard carton of this invention is shown in FIGURE 3. There the blank 110 includes the generally rectangular base portion 112 defined by parallel fold lines 114 and 116, along the long sides of the rectangle, and parallel fold lines 118 and 120, along the short sides of the panel. Fold lines 122 and 124 extend generally parallel to fold lines 114 and 116, respectively, and define therebetween long side panels 126 and 128, respectively. Fold lines 130 and 132 extend generally parallel to fold lines 118 and 120, respectively, defined therebetween short side panels 134 and 136, respectively.

Large triangularly shaped flaps 138 and 140 lie outside of fold lines 122 and 124, respectively, and small triangularly shaped flaps 142 and 144 lie outside of fold lines 130 and 132, respectively. It is to be noted that the blank 110 shown herein is not provided with the corner gusset or locking tab structure. However, the blank is formed of corrugated cardboard, preferably with the corrugations running diagonally of the blank. Also, face 138a of flap 138 is provided with cementitious material or adhesive 102' whereas the diametrically opposite face of flap 140 (not shown) is provided with a similar adhesive in a manner similar to that described with the structure of the carton 10. The zipper type opening 106 is also provided. In the simplified embodiment, the sides 134 and 136 are folded upwardly and the flaps 142 and 144 are folded inwardly and then the flap 140 is folded upwardly and inwardly with the flap 138 folded thereover and sealed thereto to form the completed enclosure.

Another modified form of this invention is shown in FIGURE 4. There the generally rectangular carton blank 210 is preferably formed of corrugated lamination with the corrugations extending diagonally of the blank. Blank 210 includes the generally rectangular base portion 212 defined by parallel fold lines 214 and 216 extending along the length of the long sides of the rectangle and pairs of spaced parallel fold lines 218 and 220 extending along the width or short sides of the panel 212. Fold lines 222 and 224 extend generally parallel to fold lines 214 and 216, respectively, and define therebetween long side panels 226 and 228, respectively. Fold lines 230 and 232 extend generally parallel to fold lines 218 and 220, re-

spectively, defined therebetween short side panels 234 and 236, respectively.

Large triangularly shaped flaps 238 and 240 lie outside of fold lines 222 and 224, respectively. Small triangularly shaped flaps 242 and 244 lie outside of fold lines 230, 232. A zipper type opening 206 is provided on flap 238. One face 240a of flap 240 is provided with adhesive 204 and the other diametrically opposite face of flap 238 (not shown) is provided with a similar adhesive as shown and described with respect to the embodiment 10 illustrated in FIGURES 1 and 6.

Opposite side edges of flaps 242 and 244 are provided with outwardly extending nibs 278, 280 and 282, 284, respectively, preferably at the intersection of the diagonal and straight side portions of the flap-s. In addition, the long side walls 226 and 228 are provided with surface cut outs 286, 288 and 290-292. When the package is assembled, it is intended that the nibs 280 and 282 would engage in the surface cuts 286 and 288 and the nibs 278 and 274 would engage in the surface cuts 290 and 292 in the upright side walls 226 and 228, as shown in greater detail in FIGURE 5. This arrangement performs a similar function to that of the several locking tabs 78, 80, 82 and 84 shown in the embodiment, preventing the unintended or accidental reverse withdrawal of the side panels 234, 236 and flaps 242, 244. However, no corner gussets are provided with the structure shown in FIG- URE 4.

The other stages of the assembly of this carton are similar to that defined with respect to the embodiment 10 in that one of long flaps is first folded inwardly with adhesive facing upwardly and the other long flap is folded inwardly over the rest of the structure with a mutually opposed adhesive coated surface so that the two may tenaciously engage together and complete the enclosure.

It can be seen from the foregoing that the present invention provides a carton blank which may be easily and quickly assembled into a substantial, rigid, generally stress free container, securely held against unintentional or accidental disassembly. It can be further seen that by forming the blank from corrugated cardboard stock so that the corrugations run parallel to pairs of edges and transverse to other pairs of edges, very little material of the basic cardboard stock is wasted in providing the blank of this invention. In fact, in the preferred form shown in FIGURE 1, only the minute area between the four gussets and the flaps 42 and 44 is wasted material.

The foregoing detailed description is given for clearness of understanding only and no unnecessary limitations are to be understood therefrom, as some modifications will be obvious to those skilled in the art.

What is claimed is:

1. A box or carton formed from a generally rectangular blank comprising: a generally rectangularly shaped main panel, two pairs of generally transversely oriented pairs of inner and outer fold lines spaced about the periphery of the main panel and defining first and second opposed pairs of side walls thereby, with first and second opposed pairs of side flaps articulated to said first and second opposed pairs of side walls, respectively, by means of the outermost of said pairs of fold lines, the inner fold line of one of said pairs of fold lines extending across the periphery of the rectangular panel inwardly of the ends of the transversely oriented pairs of side walls, thereby adapting the side Walls delimited by said inwardly positioned inner fold lines to be folded about the main panel and lie within said transversely oriented side panels when said transversely oriented side panels are folded about the inner fold lines connecting the same to the main panel, following which said side flaps may be folded inwardly over the outer fold lines in superposition relative to the main panels to form an enclosure thereby; and locking means for retaining the several panels and flaps in a closed condition, said inwardly positioned inner fold line extends across the main panel inwardly from the ends of said transversely oriented side panels a distance at least equal to the thickness of the side panels, locking gussets are articulated by means of a hinge line to said side panels defined by said inwardly positioned inner fold lines with the locking gussets having an outwardly facing locking tab spaced from the hinge line articulating the gusset to its related side panel, the lateral extent of the flap connected to the first pair of side panels terminates inwardly of the hinge line articulating the locking gusset to the side panel, the locking gusset and related side panels are notched inwardly of the outer fold line on either side of the hinge line articulating the locking gusset to the side panel.

2. A carton formed from a generally rectangular blank, comprising: a generally rectangularly shaped main panel including a first pair of generally parallel spaced inner and outer fold lines defining a first pair of generally parallel side walls on opposite sides of the periphery of the main panel and a second pair of generally parallel inner and outer spaced fold lines defining a second pair of side walls along the periphery of the main panel; first and second opposed pairs of side flaps articulated to said first and second opposed pairs of side walls, respectively, by means of the outermost of the pairs of fold lines, adapting the flaps to be folded inwardly over the main panel when the side walls are folded upwardly relative thereto about the innermost of the pairs of spaced fold lines; the first pair of side Walls having gussets extending outwardly of the opposite ends thereof and articulated thereto by means of a fold line, such gusset extensions being foldable inwardly of the side wall by means of said fold lines when the respective side walls are folded upwardly about the main panel so that the gussets will lie in a plane generally parallel to the laterally adjacent side Walls of the second pair and forming reinforcing structure therefor, the gussets being provided with outwardly facing locking tabs located on the gussets spaced from the fold line by means of which the gussets are articulated to the related side walls, the gussets are notched inwardly of the outermost fold line articulating the flap to the panel to which the gussets are related, said notch extending outwardly toward the locking tab from the fold line articulating the gusset to the side panel, the side flaps articulated to the second pair of side walls are provided with notches in the underside thereof, said notches formed inwardly of the opposite ends of the side flaps and terminating short thereof.

3. A carton formed from a generally rectangular blank comprising a generally rectangular shaped main panel including a first pair of generally parallel spaced fold lines determining a first pair of generally parallel side walls about opposite ends of the periphery of the main panel and a second pair of generally parallel spaced fold lines defining a second pair of generally parallel side a ls spaced about opposite sides of the periphery of the main panel extending transversely of the said first pair of side walls, first and second opposed pairs of side flaps articulated to said first and second opposed pairs of side walls, respectively, by means of the outermost pairs of fold lines, thereby adapting said flaps to be folded inwardly over the main panel when the side walls are folded upwardly relative thereto about the innermost of said pairs of spaced fold line; the first pair of side flaps having generally laterally extending locking tabs thereon for engagement with the second pair of side walls and flaps to lock the carton in a closed condition when the walls and flaps are folded upwardly and inwardly upon each other, the second pair of side walls is provided with locking notches spaced inwardly from the terminal ends thereof for receiving the locking tabs of the first pair of side flaps.

References Cited UNITED STATES PATENTS 1,774,299 8/1930 Stubbs et al. 22916 1,866,230 7/1932 Stubbs 229-33 3,162,350 12/1964 Miller 22931 FOREIGN PATENTS 682,854 11/1952 Great Britain. 1,405,944- 6/1965 France.

261,018 8/1949 Switzerland.

DAVID M. BOCKENEK, Primary Examiner US. Cl. X.R. 229-40, 51 

